Ever wondered how manufacturers determine the time required for each sewing operation in a garment? The answer lies in SAM Standard Allowed Minutes.
In the garment manufacturing industry, the Standard Allowed Minute (SAM) plays a vital role in determining production efficiency. SAM refers to the time, measured in minutes, allowed to perform a specific task such as cutting, stitching, or assembling a garment. This value is crucial for production planning, target setting, cost calculation, and performance measurement. Essentially, SAM is the heartbeat of garment production.
Understanding SAM is essential for manufacturers, industrial engineers, and anyone involved in garment production. It sets the foundation for smooth operations and enables manufacturers to meet delivery targets, reduce production costs, and improve overall efficiency.
In this article, we’ll explore what SAM is, why it’s important, and how you can calculate SAM using two key methods.
What is SAM?
Standard Allowed Minute (SAM) is the time allotted for an operator to complete a specific operation or task, expressed in minutes. It is used to measure the total time required to produce a garment, from cutting the fabric to the final assembly. SAM plays a critical role in garment production planning, as it helps calculate labor costs, set production targets, and establish timelines for each operation.
SAM is also used to measure the work content of each individual operation. For example, the process of sewing a sleeve, attaching buttons, or hemming a dress can be assigned a specific SAM value. Industrial engineers use SAM to ensure that production lines are balanced, operators are performing efficiently, and garments are produced within the allocated time.
How is SAM Calculated?
Methods to Calculate SAM
There are two widely used methods for calculating SAM:
- Time Study Method
- Synthetic Data Method
SAM Calculation Using Time Study
The time study method is the most common manual calculation method for SAM. It involves observing the operator and measuring the time taken to complete a task over several cycles.
Steps to Calculate SAM using Time Study:
- Select the operation: Begin by selecting the operation for which you need to calculate SAM. This could be a simple task such as attaching a collar, stitching a seam, or performing any other repetitive task.
- Measure the cycle time: The cycle time refers to the time it takes to complete a full cycle of the task. For example, in sewing, the cycle may involve picking up the fabric, stitching, and dispatching the finished part. Use a stopwatch to record the observed time for at least five complete cycles. Make sure to discard any abnormal readings caused by machine malfunctions or operator errors. The observed time should represent the average time taken for the operation to be completed under normal conditions.
- Calculate the average cycle time: Once you have recorded the time for five cycles, calculate the average of the times. This average represents the cycle time for the operation.
- Assign operator performance rating: The operator’s performance is rated as a percentage, usually between 75% and 125%. This performance rating measures how efficiently the operator performs the task compared to a standard operator. For example, an operator working faster than average might receive a rating of 120%, while a slower operator might be rated at 80%.
- Calculate basic time (SMV): Multiply the cycle time by the performance rating to get the Standard Minute Value (SMV) or basic time. This value represents the minimum time required to perform the task.
- Basic Time or SMV=Cycle Time X Operator Rating
- Add allowances: No operator can work at 100% efficiency for the entire day, so allowances are added to account for rest breaks, machine delays, and fatigue. These allowances can vary from 10% to 20%, depending on the organization.
- SAM=(Cycle Time X Operator Rating) + Allowances
SAM Calculation Using Synthetic Data
The synthetic data method uses predefined data and specialized software, such as GSD or PMTS, to calculate SAM. This method relies on standardized motion codes that measure the time required for specific motions, such as picking up fabric, aligning it, or stitching.
Steps to Calculate SAM using Synthetic Data:
- Select the operation: Choose the operation you want to calculate SAM for, just as in the time study method.
- Record all motions: Break down the task into individual motions, such as picking, aligning, or stitching. Each motion is assigned a code in the software.
- Input additional details: Enter specific details like machine type, machine speed, seam type, stitch class, and garment style into the software. This information is crucial for the software to calculate the Time Measurement Units (TMU) for each motion.
- Convert TMU to minutes: Once the software calculates the TMU value (1 TMU = 0.0006 minutes), convert it to minutes to get the Standard Minute Value (SMV). After applying allowances, the software will provide the final SAM value.
Why SAM is Important in Garment Manufacturing?
SAM provides several benefits to garment manufacturers:
- Production Planning: SAM allows manufacturers to determine how long it will take to produce a specific garment or perform a particular task. This information helps in effective production planning and scheduling.
- Cost Calculation: Since labor costs are a significant part of garment manufacturing, SAM helps calculate how much labor cost is involved in producing a garment. Knowing the SAM for each operation allows factories to set accurate prices.
- Performance Measurement: SAM helps measure the performance level of each operator by comparing their actual time to the standard time (SAM). This data allows managers to identify and improve underperforming operations.
- Target Setting: SAM is used to set production targets for operators based on how much work they can complete within a shift.
- Standardization: SAM helps standardize production processes across different garments and garment styles, ensuring consistent quality and efficiency.
How SAM Affects Garment Production
SAM (Standard Allowed Minute) plays a crucial role in streamlining production and increasing efficiency in the garment manufacturing industry. By accurately calculating SMV and SAM, manufacturers can improve production planning, allocate resources more efficiently, and ensure that operators are working at their optimal performance level. SAM also allows factories to adapt to different garment styles by modifying production processes based on the time required for each task.
By using SAM, managers can monitor performance, adjust garment style production times, and improve overall efficiency, ensuring that garments are produced on time and within budget.
With these calculation methods, whether through time study or synthetic data, SAM helps manufacturers achieve better production outcomes and make informed decisions. Accurate SAM calculations lead to better planning, reduced costs, and higher productivity, making it an essential tool in the garment manufacturing industry.
Reference Links:
- Fashion 2.0: Understanding Standard Allowed Minutes
- Apparel Resources: SAM in Garment Manufacturing
- OCS: How to Calculating Standard Allowed Minute
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What is TMU? Can you please explain.
How can we reduce SAM of a particular operation? can you give few example , operation – Collar Making ?
Tks